Customized prescription product packaging and method and system for producing customized prescription product packaging

ABSTRACT

This invention provides packaging for housing at least one prescription product comprising customized graphics on at least some surface area of said packaging, said customized graphics being selected by the individual doctor prescribing said prescription product or the patient to receive said prescription product. This invention further provides the method and system for producing customized packaging which houses at least one prescription product, wherein said packaging is customized by the individual doctor prescribing and/or said patient receiving said at least one prescription product comprising the steps of:  
     receiving an order for at least one prescription product from said doctor or a refill order from said patient; and  
     printing out customized graphics specified by said doctor or said patient for said package for at least one prescription product.

FIELD OF THE INVENTION

[0001] The present invention relates to customized prescription productpackaging, and the method of producing customized prescription productpackaging.

BACKGROUND OF THE INVENTION

[0002] The packaging of contact lenses is well known in the contact lensmanufacturing technology. For short-term use or single wear contactlenses, such packaging arrangements generally consist of blister packswhich are employed for the storage and dispensing of the hydrophiliccontact lenses by a medical practitioner or sale to a patient who wearsthe contact lenses. Typically, the blister packs have a plastic bowlshaped area to receive the contact lens and aqueous solution, and acover, such as a heat-sealed lidstock which may consist of one or morepolymeric or foil layers. Several blister packs may be removablyattached to each other usually by the lidstock to form an array ofblister packs. An example of a blister pack which is adapted to providea sterile sealed storage environment for a disposable or single-usehydrophilic contact lens, wherein the lens is immersed in a sterileaqueous solution is described in U.S. Pat. No. 4,691,820 to Martinez;which is assigned to the common assignee of the present invention, andthe disclosure of which is incorporated herein by reference.

[0003] Typically, one or more of the arrays of blister packs are placedin a box or carton for sale to the patient. Conventionally, thepluralities of blister packs containing the contact lenses in thesterile aqueous solutions are packaged and stored in cartons eachcontaining a specified quantity of the blister packs; for example, 15 or30 blister packs or other suitable quantities. Generally, the cartonsare constituted of cardboard or paperboard possessing rectangularconfigurations and are imprinted in one or more colors with suitableidentifying legends, logos, decorative indicia and/or instructions inthe use of the contents, and information regarding the manufacturer, asmay be required by various government regulations and/or statutes.

[0004] The cartons are usually placed in large storage boxes proximatethe manufacturing lines where the lenses were produced, packaged, andsterilized. The large storage boxes containing the cartons are forwardedto distribution centers or warehouses and stocked at those locations. Inthe event that no further processing of the carton contents is required,upon the receipt of shipping and/or sales orders, the large storageboxes are eventually pulled from stock, the cartons containing theproduct, such as the blister-packaged contact lenses, are removed fromthe boxes, separated into individual orders which may consist of variousdifferent products, and the orders shipped to prospective customers,such as domestic or foreign distributors, physicians, optometrists or topotential users of the contact lenses.

[0005] Both the lidstock and the cartons may contain some informationwhich is printed upon the lidstock or carton just prior to the time thatthe lidstock is sealed onto the blister or just prior to the time thatthe arrays of blister packs are placed in the cartons. The informationwhich is added to the lidstock or the carton at this time typically islimited to the power, axis, cylinder, expiration date and lot number.All the other information and logos are usually present on the lidstockand cartons prior to packaging the contact lenses in the manufacturingline.

SUMMARY OF THE INVENTION

[0006] This invention provides packaging for housing at least oneprescription product comprising customized graphics for said packaging,said graphics are customized by the individual doctor prescribing and/orthe individual patient receiving said at least one prescription product.

[0007] This invention further provides the method and system forproducing customized packaging which houses at least one prescriptionproduct, wherein said packaging is customized by the individual doctorprescribing and/or said patient receiving said at least one prescriptionproduct, said method comprising the steps of:

[0008] receiving an order for at least one prescription product fromsaid doctor or a refill order from said patient; and

[0009] printing out customized graphics specified by said doctor or saidpatient for said package for at least one prescription product.

[0010] This invention provides packaging and a method and system forproducing customized packaging for said at least one prescriptionproduct. The benefit of this invention is to provide the doctors withthe ability to customize the prescription product packages for his orher patients. The doctor can add his or her name, telephone number(s),e-mail address, website, street address, appointment information,greetings, a picture of the doctor, office, local landmark, and/or anyother desired picture or information directly to the packaging materialsfor the prescription product. The preferred prescription product is acontact lens. This invention is particularly beneficial for doctors toprovide cartons having customized graphics to new patients who may havebeen fitted with trial pairs of contact lenses and must return to thedoctor for a follow-up appointment. It also provides a vehicle for thedoctors to advertise their practices.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Reference may now be had to the following detailed description ofthe preferred embodiments of the invention, taken in conjunction withthe accompanying drawings; in which:

[0012]FIG. 1 illustrates a perspective top and side view of a blisterpack array with customized graphics;

[0013]FIG. 2 illustrates a perspective top and side view of a cartonwith customized graphics;

[0014]FIG. 3 illustrates a top view of an insert with customizedgraphics;

[0015]FIG. 4 illustrates a top view of a label having customizedgraphics for a carton; and

[0016]FIG. 5 is a schematic of a top view of a system for printing outlabels having customized graphics for adhering to a carton.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The invention will be described for the preferred prescriptionproduct, a contact lens; however, any prescription product could besubstituted for the contact lens. Examples of other prescriptionproducts include medications, spectacles, medical devices, or the like.

[0018] The “identification means” is a number, bar-code, two-dimensionalmatrix, three dimensional matrix, inductive transmitting/receivingdevice, or radio frequency chip, or the like. Preferably eachidentification means contains some unique information for every parthaving one. Identification means may be machine readable and/or humanreadable, preferably at least machine readable. A machine readableidentification means preferably has information stored in a databaseassociated with the identification means. For packaging, the informationstored in the database associated with the identification means may notbe present on the packaging in human-readable form. That is, the onlyway to know which product is in the packaging is to access theinformation in the database by inputting the identification means intothe database, via a bar-code reader or the like.

[0019] As shown in FIGS. 1, 2, and 3 the packaging having customizedgraphics which houses at least one contact lens can be part of any ofthe packaging for the contact lens. Typically, contact lens packagingcomprises primary packaging and secondary packaging. The primarypackaging is the packaging adjacent to the contact lens, the secondarypackaging surrounds the primary packaging. There can be any number oflayers of packaging for the contact lens; however, in the preferredembodiment, there is primary packaging and secondary packaging. Thecustomized graphics can be added to the primary, and/or secondarypackaging and/or it can be a package insert, typically placed within thesecondary packaging. The customized graphics can be an alphanumericmessage, picture, photograph, and/or the like, or combinations of theabove.

[0020] The primary packaging for a contact lens is preferably a blisterpack with a lidstock, but it can take any form, e.g. a glass bottle,cans, trays, pouches, e.g. form-fill-and-seal pouches, as long as itprovides adequate protection for the contact lens. FIG. 1 shows ablister pack array 10 having customized graphics. The blister pack array10 consists of five blister 204; packs 11. Each blister pack 11 consistsof an individual base 12 all five of which are interconnected by acontiguous lidstock 13, which is scored so that the individual blisterpacks 11 can be detached from the array 10. Each base 12 preferablycomprises injection-molded or thermoformed plastic incorporating amolded cavity 15 which is surrounded by an outstanding planar flange 18about the rim of the cavity 15. A flexible cover sheet or lidstock 13 isadhered to the surface of the flange 18 so as to sealingly enclose thecavity 15 in a generally air and liquid-tight mode. Within the cavity 15of the base portion, a contact lens (not shown) is immersed in a sterileaqueous solution (not shown). Preferably the contact lens is ahydrophilic contact lens manufactured of materials known to those ofordinary skill in the art. The customized graphics 14 shown are presenton the lidstock 13 and indicate the patient to receive the contact lensin each blister pack, and which eye of the patient the contact lensshould be placed in. The customized graphics 14 state on the lidstockfor each blister pack: “CONTACT LENS FOR JOAN'S LEFT EYE”. There may beno prescription information e.g. power for spherical contact lenses orpower, cylinder, axis for toric contact lenses present on the packaging,only information indicating who the product is for, and directions forits proper use. The packaging may only be identified and tracked by themanufacturer by at least one identification means, also referred to as aproduct identification means, preferably a machine readableidentification means present on the packaging, preferably on at leastthe secondary packaging, more preferably present on both the primarypackaging and secondary packaging for contact lenses. The informationassociated with the product identification means, such as, SKU, lotnumber, expiration date, can be stored in one or more databases. Theinformation is accessible when the product identification means isinputted into a computer, which can access the database.

[0021] Presently, it is preferred that the packaging for the contactlenses comprise primary and secondary packaging. The preferred secondarypackaging is a carton, but it can take any form, such as, bags, plasticwraps, envelopes, pouches, cans, boxes, bottles, or trays. The secondarypackaging preferably houses multiple primary packages. The preferredsecondary packaging is shown in FIG. 2. FIG. 2 shows a carton 20, whichpreferably houses multiple contact lenses each in primary packaging(such as one more of the arrays shown in FIG. 1). The rectangular carton20 preferably comprises paperboard. The carton 20 includes flat top wallpanel 21 and opposing bottom wall panel (not shown) respective frontpanel 25 and opposing rear panel (not shown), and opposite end walls 24(only one shown) which are sealed through an adhesive or gluedconstruction as is known in the carton forming technology. The top wallpanel 21 includes a downwardly depending front flap 26 having acentrally located latching tab 27 at a lower edge thereof which isadapted to be tucked into a cooperating latching slit (not shown)centrally formed in the front panel 25 to facilitate reclosing of thecarton 20. The top wall panel 21 is adapted to be swung upwardly about arear hinge line 28 to open the carton 20. The top wall panel 21 of thecarton is shown having the customized graphics 22, 23 which consist ofalphanumerics 22 and a picture 23. The alphanumerics 22 state: “CONTACTLENSES FOR JOAN SMITH PROVIDED BY DR. JONES”. The picture 23 is aphotograph of the doctor, Dr. Jones, who prescribed the contact lenses.

[0022]FIG. 3 shows a third embodiment of the invention in which thecustomized graphics are added to a package insert. The package insertcan be a paper or any object, e.g. a toy, a mirror, etc., which is addedto the packaging. FIG. 3 shows the insert 30 as a piece of paper, andthe customized graphics 31 is an alphanumeric message which states:“These contact lenses are provided to Joan Smith by DR. JONES, O.D. Ouroffice will call you in one month to schedule a follow-up. In theinterim if you have any problems with these contact lenses, please callmy office at 555-5555. Your eyes are important to me.” The packageinsert paper 30 can be folded up to fit into the secondary packaging,e.g. carton. The customized graphics shown in the figures are exemplary.Any alphanumeric message, picture, or photograph selected by the doctor,or patient could be used.

[0023]FIG. 4 shows a label 40. The label may be adhered to blank areasof the packaging or it may be an over-label, meaning it may be adheredto areas of the packaging which are partially or fully labeled fordistribution. The label 40 is preferably an adhesive sticker. The label40 as shown is shaped for use on a carton similar to the carton shown inFIG. 2. The label 40 consists of a top layer 47 comprising paper,polymer, (e.g. polyvinylchloride film) or metal film, preferably paper.Preferably there is an adhesive layer (not shown) coated on the backside of the top layer 47. The label 40 may be attached to a peel layer(not shown) which the top layer 47 and the adhesive layer can be peeledfrom before attaching the label 40 to the package. Preferably, theadhesive is a permanent adhesive, e.g. Avery Dennison adhesive LP-430Permanent/Emulsion Acrylic with service temperature range −54 to +93°C.; Avery Dennison adhesive S-4600 Permanent/Acrylic with servicetemperature range −40 to +80° C. Alternatively, the label 40 may onlyconsist of a top layer 47 and the adhesive can be applied to thepackaging before the top layer is applied to the packaging. The label 40has multiple types of customized graphics 41, 42, and 43. The label 40has a doctor's photograph 41, a picture of a sail boat 42, and analphanumeric message 43 indicating that the contact lenses are “Providedby Dr. Sailor (555) 555-5555”. The photograph, picture and alphanumericmessage are all selected by the doctor. The doctor could specify (or apatient may select) a picture which he/she knows is well suited for apatient, e.g. a horse for a horse-lover.

[0024] As shown in FIG. 4, the label may comprise additional informationsuch as a product identification means 45, and a label identificationmeans 46, preferably both identification means are machine-readableidentification means. The product identification means 45 is used toidentify the type of the contact lenses and the prescription of thecontact lenses that are within the carton to which the label 40 is to beadhered to. The optional label identification means 46 can be used toidentify the specific label 40, so that it can be tracked on and off thecarton, so that the label is put on the correct carton, and so theproduct is sent to the proper recipient, either the patient or thedoctor. Also, in the preferred embodiment, the label identificationmeans is used through the customized graphics printing system fortracking the quality of the label. Alternatively, the labelidentification means 46 may be in a portion of the top layer 47 of thelabel which stays with the peel layer when the top layer 47 is removedfrom the peel layer, preferably just before adhering the label to thecorrect carton.

[0025] Also alternatively, the product identification means 45 may notbe on the label and is present instead on an area of the packaging whichis not covered when the label 40 is put on the packaging. If the labelidentification means is not present on the label the order informationcan be associated with the product identification means in the databaseand the product identification means can be used to track the packagingafter the label is adhered to the packaging. Alternatively, the labelidentification means can be product identification means if the labelidentification means is the only identification means present on thepackaging.

[0026] The label 40 is shown having some standard graphics 44 which arenot customized for either the doctor and/or the patient and may bepresent on the label 40 before (or added to the label 40 after) thecustomized graphics are printed onto the label 40, or the non-customizedgraphics can be printed onto the label 40 at the same time that thecustomized graphics are added. In short, the customized andnon-customized graphics can be added to the packaging in any sequence.Non-customized information includes, e.g., identifying legends and logospertaining to the company manufacturing and/or marketing the product,instructions pertaining to the use of the product packaged in thecarton, decorative indicia the contents, directions for use, warningsabout dispensing the prescription product without a prescription, andthe like.

[0027] If the customized graphics are added to the primary package andthe primary package comprises a blister pack comprising a bowl andlidstock, it is presently preferred that the customized graphics areadded to the lidstock. Either the lidstock can be printed on directly toadd the customized graphics or the customized graphics can be addedindirectly to the lidstock by printing out a label having customizedgraphics and adhering the label to the lidstock. Alternatively, a labelhaving a blank area can be adhered to the lidstock and printed on afteradhering to the lidstock. The preferred methods for printing outcustomized graphics on labels will be described in more detail below.(The preferred method described below is presently used to print outlabels for cartons, but it can be modified to print out labels forlidstock, instead.) In the embodiment shown in FIG. 1, the customizedgraphics 10 were added to the lidstock 13 directly by printing onto thelidstock. Either an area on the lidstock can be reserved for thecustomized graphics or the customized graphics can cover the entirelidstock.

[0028] It is presently preferred that the customized graphics are addedto the secondary packaging. Presently the preferred secondary packagingis a carton. The customized graphics can be added to either the outsideor inside surface area of the secondary packaging. The customizedgraphics are preferably present on at least 5 percent of the outsidesurface area of the secondary packaging, more preferably at least up to25 percent, and most preferably at least 50 percent of the outsidesurface area of the secondary packaging. Preferably the customizedgraphics comprise a background image which is present on at least 30percent, more preferably at least 60 percent and most preferably atleast 80 percent of the surface area of the secondary packaging. For acarton, preferably, at least one panel or wall has some customizedgraphics, more preferably at least two panels have some customizedgraphics, most preferably at least three panels have some customizedgraphics. Alternatively or in addition to the customized graphics on theoutside surface of the secondary packaging, the customized graphics cancover a portion of the inside surface area of the secondary packaging.Presently, it is preferred that the outside surfaces of the secondarypackaging carry the customized graphics.

[0029] The customized graphics can be added to the secondary packagingeither directly or indirectly. The secondary packaging can be printed ondirectly or a label may be adhered to the secondary packaging and thenprinted upon. For indirect printing, the customized graphics can firstbe printed onto a label such as the one shown in FIG. 4, such as anadhesive label, which can then be adhered to the secondary packaging.The label can be small or large. The label can be used as part of themeans to seal the secondary packaging, or the label can cover a portionof the outside surface area of the secondary packaging which is not nearany of the sealing means, that is flaps, tear strips, insert pieces,seams, etc. of the secondary packaging. Although printing on labelsfirst has the drawback that it requires a second step of adhering thelabels to the packaging, this method is presently preferred, because notall the contact lenses ordered will be produced for doctors or patientswho will want to have the customized graphics added to the packaging.The preferred method of printing out labels will be described in moredetail below.

[0030] Alternatively, the customized graphics can be printed directlyonto the secondary packaging. The secondary packaging may be assembledor disassembled at the time of printing with or without the primarypackages within. For example, if the secondary packaging is a carton,the customized graphics may be printed on the carton as a flat cartonblank or as an assembled carton which is empty. A support for anassembled empty carton which can be used during printing on the cartonis disclosed in Duis et al, “METHOD AND SUPPORT FOR CARTON”, U.S. Ser.No. 09/217,879, filed Dec. 21, 1998 (VTN-442) incorporated herein byreference. Alternatively, the carton may be printed on directly afterthe contact lens primary packages are inserted into the carton, by laseror ink jet printing. Alternatively, a label having a blank area may beadded to the carton and then the customized graphics may be added to thelabel. If the secondary packaging is not a carton the preferred printingtechniques for printing on the secondary packaging can be adapted to thesecondary packaging materials used.

[0031] Alternatively, the customized graphics can be printed onto aninsert which can be inserted into the secondary packaging for example ina manufacturing line before the secondary packaging is sealed.

[0032] Printing on the packaging, e.g. primary packaging, secondarypackaging, and/or package insert can be by any printing method e.g. bythermal, laser, electrophotographic, ink jet, and pad printing. Somemethods are better suited for certain types of packaging materials,which are known to a person of ordinary skill in the art. The preferredmethod for printing on a label will be described below.

[0033] For each embodiment, the method of printing the customizedgraphics begins with an order from a doctor for prescription contactlenses. The orders are received according to methods known in the priorart, e.g. mail, telephone, internet, fax, except that the order methodsare modified so that the doctors/patients have the ability to indicatewhat customized graphics they would like to have on the packaging andoptionally where on the packaging the customized graphics are to beplaced. Preferably, there will be a large collection of pictures,photographs, and messages to select from, and each item in thecollection will be coded and stored in computer memory, which will beaccessible to the printing apparatus. In addition, preferably, thedoctors can specify pictures, photographs or messages outside of thecollection. For example, when Dr. Jones calls in his order, he canspecify which cartons, if any, to print the photograph of himself whichhe previously provided to the manufacturer, and is stored in thecomputer memory which is accessible to the printing apparatus. Dependingupon what packaging is to receive the customized graphics, that is,primary packaging, secondary packaging, or inserts and if the customizedgraphics will be added to the packaging in-line or off-line willdetermine how the order information will be processed. If the customizedgraphics are to be added to the primary packaging, then the orderinformation will preferably be sent to a manufacturing line which has aprinter for the lidstock or labels for the lidstock so that thecustomized graphics can be added to the primary packaging prior toplacing the primary packaging in secondary packaging. If the customizedgraphics are to be added to the secondary packaging, the information canbe sent to a contact lens manufacturing line which will either printdirectly onto the secondary packaging or will print onto a label for thesecondary packaging either prior to or after putting the primarypackages of contact lenses into the secondary packaging. The packagingwhich has been modified preferably will be marked with an identificationmeans, preferably a machine readable identification means identifying towhom the order should be sent so that it can be tracked and sent to thecorrect doctor or patient. Alternatively, often packaging has a uniquemachine-readable code (e.g. product identification means) present on itsexterior which is used to identify the product and other information,such as, lot number, stock keeping unit (SKU), and expiration date. Thismachine-readable code can have additional information assigned to it(which is preferably stored in a database) identifying that the packagehas received customized graphics and to whom the product should berouted. Alternatively or additionally, the exterior of the packaging canbe marked with a human-visible indicator signifying that the package hasreceived customized graphics which may be tracked by an operator or willassist a quality check by an operator before shipping an order.

[0034] Presently, the preferred method is to manufacture the contactlenses, place the contact lenses in primary packaging, place multipleprimary packages of contact lenses in secondary packaging and sterilizethe lenses by the customary methods described in the prior art, and thento add the customized graphics to the secondary packaging using a labelprinted off-line, and preferably added off-line. Preferably, the orderinformation for the customized graphics is sent to a customized graphicsprinting system which is separate from the contact lens manufacturingline. The customized graphics printing system will print out labelswhich will cover at least a portion of the outside surfaces of thesecondary packagings, e.g. cartons. Preferably, the doctor's orders willbe picked from stock in the customary method of assembling the orderedcontact lenses in their customary secondary packaging. The labelsproduced on the customized graphics printing system will then be matchedup with the secondary packaging for each doctor's order and then thelabels will be adhered to the secondary packaging either in an automatedmethod or manually. After the labels are adhered to the secondarypackaging in accordance with the doctor's order, the order will beshipped directly to the doctor or patient.

[0035] In an alternative method, the customized graphics can be addedin-line, that is, in the manufacturing line in which the contact lensesare produced, and placed in the primary packaging and preferably alsoplaced in the secondary packaging. In the in-line mode, the orderinformation will be provided to the manufacturing line which isproducing the ordered contact lenses and the customized graphics will begenerated right in the manufacturing line, and added to the packagingin-line. If the customized graphics are to be added to the primarypackage, at about the time the ordered contact lenses are placed in eachof its primary packaging the customized graphics will be added to, forexample, the lidstock, and then the lidstock will be heat-sealed to thebowl. If the customized graphics are to be added to the secondarypackaging, the carton preferably will be printed on in the manufacturingline prior to placing the primary packagings into the carton and priorto sealing the carton. The printing can be accomplished by any of themethods listed above. The exterior of the packaging, for example thesecondary packaging, will preferably have an identification means,preferably a machine-readable code, to which the information inconnection with the customized graphics will be stored for delivery tothe correct recipient of the contact lenses.

[0036] In the preferred method, the graphics will be added off-line, andthere will be one or more computerized databases which will track thedoctors names and the selected customized graphics. As the orders forprescription products come in, as described above, and assembled in adatabase the order information will be searched for a request forcustomized graphics or for a doctor's name who has requested customizedgraphics on all of his/her packaging. (Alternatively, the orderinformation will be searched for the patient's name that has requestedthe customized graphics). When one or more orders are found which haverequested customized graphics, the customized graphics information willbe sent to a customized graphics printing system. In the preferred modelabels having customized graphics will be printed by the customizedgraphics printing system. Afterwards, the labels will be matched up withthe correct packaging, preferably cartons containing the ordered contactlenses. The preferred method of assembling or picking the orderedproducts is according to the method and by using the apparatus andmethod disclosed in Duncan et al, “Apparatus and Method for AutomatedWarehousing and Filling Orders for Multi-Item Inventories”, U.S. Ser.No.______, filed concurrently herewith, (VTN-453), incorporated hereinby reference. The picked (assembled) order will be deferred to theoff-line customized graphics printing system for the application ofprinted labels having the customized graphics to the cartons to receivethe labels in accordance with the orders.

[0037] The preferred off-line method for producing labels havingcustomized graphics comprises a printing step, and one or morequality-checking steps. More preferably the method additionallycomprises a varnishing step. Most preferably the method additionallycomprises one or more cutting steps. These and other steps will bedescribed in relationship to the preferred system for printing outlabels having customized graphics as shown in FIG. 5.

[0038]FIG. 5 shows the presently preferred customized graphics printingsystem 500 comprising a printer 502, a quality check station 505, avarnish application apparatus 508, a cutting apparatus 509, a labelapplicator 513, and preferably shop floor controller 512. The shop floorcontroller 512 is a computer, or the like, tracks the labels within theprinting system 500. The shop floor controller comprises memory,programs, processor, databases, and the ability to receive information,e.g., from parts of the printing system 500, and output information, andinstructions, e.g., which effect the function of parts of the printingsystem. The operation of the shop floor controller 512 will be describedbelow.

[0039] Preferably orders for contact lenses and customized graphics arereceived by a separate order processing system and communicated to theshop floor controller 512, preferably from a central customer ordermachine server (not shown). Customer orders can be received by phone,mail, internet, facsimile, or by any method. Some order takingprocedures are disclosed in U.S. Pat. No. 4,958,280, incorporated hereinby reference, others are known in the art. Preferably, only the ordersto receive customized graphics are communicated to shop floor controller512. Order information includes, e.g. an order number, date of order,the person ordering, products ordered, the customized graphics to beprinted on the cartons, and shipping address. In the preferred system500, the shop floor controller 512 sorts the information in the ordersfor the labels that are to be printed onto the web, and stores thisinformation in a database. FIG. 6 shows a database 60 which can be usedto store the sorted order information. FIG. 6 is only exemplary and moreor fewer fields can be used to track the labels in the printing system500 which would be apparent to a person of skill in the art. Thedatabase 60 includes fields for the order information such as the ordernumber 61 (each order has an order number), and product SKU 62identifying the type of product ordered, and the customized graphics 63,64 which was specified by the doctor and/or patient for the product.Graphics field 63 specifies, e.g., background art. Graphics field 64specifies, e.g., a message. More or fewer fields can be provided asdesired. Other fields, e.g., the SKU field can indicate additionalnon-customized graphics to be printed onto the label. One or more of thefields in database 60 may be keyed to additional databases which mayprovide additional information when needed, e.g. the order number may bekeyed to a database having the doctor's name and address, and/or theidentifying numbers in the graphics field are keyed to databases whichindicate what graphics will be printed by the printer 502.

[0040] Preferably labels from the same order are printed adjacent to oneanother, and labels having similar graphics (e.g. the same backgroundpicture) are printed close to one another on the web, and a labelidentification means is assigned to each label. The sorted labelinformation is communicated to the control unit 501 for the printer 502.A spool 550 of a web of label material preferably 32 cm wide is fed intoa digital printer 502. The label material preferably consists of apolyvinylchloride coated paper top layer with an adhesive coated back,and a removable peel layer as described in reference to FIG. 4. Anexample of a commercially available web is a white-pigmented PVC withmatte imprintable top coat on paper having an adhesive layer, such asDatacal PLV-400-FW Opaque MT/C-354 V-29 S50K-8, available from FlexiconCo. In the preferred mode the web is blank and not pre-cut or scored;however, in alternative embodiments the web could be pre-cut, scored,and/or have non-customized graphics pre-printed on the web. For example,the labels could be printed individually instead of on a web, and/or thelabels could also have the brand information pre-printed on them. Atpresent, there are preferably at least 5,000 labels printed onto the webon each spool. After all the labels to be printed onto a first web havebeen printed onto the first web, the first spool 550 is removed from theprinter 502 and replaced with a second spool 550 having a blank secondweb.

[0041] The digital printer 502 preferably has the ability to vary 100%of the text and graphics for each label. The preferred printer isavailable from Xeikon or Indigo. The control unit 501 for the printer502 controls the printing of the labels and instructs the printer 502,which customized graphics, and contact lens information, if any, toprint on the labels as instructed by the shop floor controller 512. Eachlabel also preferably has some label identification means, printed ontothe label or on the web next to the label so that the label can betracked. Unique information associated with the label identificationmeans 65 is stored in database 60 in the shop floor controller 512preferably with the location of each label on the web (preferably infields 67, 68, 66 for row column and spool number, respectively), thecustomized graphics 63, 64 specified by the doctor or patient, and theproduct SKU 62 to receive the label. After the web moves through theprinter 502 it is accumulated in an accumulator 504 before passingthrough a quality check station 505 which preferably uses visualinspection equipment 520, such as a spectrophotometer or densitometer tocheck the color density and registration of the toners, pigments ordyes. Densitometers and spectrophotometers useful for this applicationare available from Gretag Macbeth, such as Spectro Eye SpectrophotometerD200-11 Process Densitometer, and D19C Densitometer, and available fromX-Rite, Inc., such as SP99 Multi-Angle Spectrophotometer, and 408 ColorReflection Densitometer. Presently, the densitometer is hand-held;however, a fixed densitometer may be used in the method of thisinvention. Additionally, an operator can perform a subjective evaluationof the labels.

[0042] Presently, the visual inspection equipment 520 may continuouslycheck the quality of the graphics and provide feedback to the controlunit 501 which will cause the printer to automatically make adjustments,or will notify an operator if the printer cannot self-correct a printingproblem. If the print quality is below a certain level, the labels inthat area of the web will be rejected, which will be noted in the labelcontrol system 503 (computer comprising processing instructions andmemory), and communicated to the shop floor controller 512 (computercomprising processing instructions and memory) which will schedule therejected labels for reprinting. The rejection will be noted in field 69of the database 60,and the shop floor controller 512 will instruct thatthe rejected label be reprinted. This can be accomplished by moving thefields 61, 62, 63, 64 for any rejected labels into a later record in thedatabase with other incoming order information, while maintaining therejected label information in the other fields for tracking purposes.

[0043] Preferably, an operator at the quality check station 505 will doa visual inspection of the labels on the web at set intervals, e.g.every 15 minutes. At that time an operator will scan the labelidentification means on the web with a handheld scanner 519 which willinput at least one label identification means in the area of the webwhich is being inspected into a label control system 503. The handheldscanner 519 preferably is a bar code scanner. If there is a problem withthe labels, the operator will communicate through the handheld scanner519, via a keypad or the like, to the label control system 503 that thelabels have failed inspection, and all the labels printed since the lastoperator inspection are to rejected. The rejected labels since the lastinspection will be determined by the label control system 503, andcommunicated to the shop floor controller 512. The rejection of thelabels will be noted in database 60 in field 69 and eventually thoselabels will be reprinted.

[0044] After the quality of the print is checked the web is rewound in arewinder 506. The core of each spool 550 has an identification means,preferably a machine readable code, such as a bar code or the like, sothat the shop floor controller 512 and label control system 503 cantrack each spool 550, and associate in the database 60 theidentification means of the labels with the spool 550 on which thelabels have been printed. (The label control system 503, preferably hasa database similar to database 60). If individual labels on the spool donot pass inspection, or if the whole spool does not pass inspection, thecontrol system 512 will instruct the printer to reprint the labels andupdate the database 60 and also communicates to the label control system503 the new location (row, column and spool) of the reprinted labels.Preferably if any of the labels for a single order do not passinspection, all the labels in an order will be reprinted on a new spoolto keep all the labels for the same order together.

[0045] Next, the web on the spool will preferably be unwound on unwinder507, and fed into a varnish station 508 in which the web, particularlythe labels on the web, will receive a UV radiation cured varnish toimprove their looks, and increase the labels' abrasion resistance. Anexample of a suitable varnish is INXCURE UV FLEXO P/I COATING which canbe applied by, for example, a Belmark varnish applicator, whichcomprises anilox rollers. Preferably the web is inspected after theapplication of the varnish to be sure that the varnish was correctlyapplied and to check for any other flaws or errors. The inspection canbe by an operator or by visual inspection equipment (not shown) similarto the apparatus and method described above. The inspector willpreferably use a second handheld scanner 519 to input the identificationmeans of the labels checked, and again individual labels or the entireweb may be discarded if there is a problem with the varnish applicatorand labels do not pass inspection. If the web is to be discarded thelabel control system 503 will note the identification means of thespool, and communicate this information to the shop floor controller512, which will update the database 60, particularly field 69, and whichwill instruct the printer 502 to reprint all the labels on the spool. Ifonly certain labels are to be discarded, the label control system 503will note the label identification means of the labels that did not passinspection, and will communicate this information to the shop floorcontroller 512 which will update the database 60 and which will instructthe printer 502 to reprint the labels that are to be discarded.Preferably all the labels in an order will be reprinted together on asingle spool.

[0046] After inspection, the web is fed into a die cutter 509 which cutsthe labels through the top layer of the web, and in a next step the toplayer of the web around the labels is removed from the web, leaving thelabels on the peel layer. In the preferred embodiment two separateapparatuses manufactured by Preco perform the just-described steps. Inthe preferred embodiment, multiple, e.g. three columns of labels areprinted on the web. After cutting the labels, the web is cut widthwiseinto smaller reels 551, e.g. three reels, in a slitting machine 510. Thereels are tracked by a machine-readable code on the core of each reel.Prior to slitting the web, the label control system 503 updates itsdatabase by assigning the labels in each column on the spool to one ofthree reels, which is noted in field 70, when the reels and spool aremounted upon the slitting machine. The labels are preferably printed onthe web, so that labels for products in the same order are printedadjacent to one another in the same column. As shown in FIG. 6, thethree products for order number 10,175 are printed in column 1 of spool2.

[0047] Presently, labels are only printed for products which are ininventory; therefore, any reel 551 can be selected by an operator andput on the label applicator 513. When the machine readable code for theselected reel is inputted into the label control system 503, preferablyvia a reader (not shown) located on the label applicator 513, theproducts onto which labels are to be adhered are pulled from inventoryand sent to the customized graphics printing system 500. In analternative embodiment, each reel 551 can be set aside until all thecartons that are to receive the customized labels on that reel have beenpicked from inventory. In either embodiment, the orders for which thelabels are ready for placement on the products are communicated from theshop floor controller 512 to order picking and/or assembly equipment(not shown) which picks the cartons from inventory. Preferably, thecartons which are to receive the labels are transported to the labelapplicator 513 on a conveyor 514 (cutaway section shown), preferably thecartons are in the same sequence as the labels for the cartons on thereel 551. Alternatively, the cartons could be transported in assembledorders in a container or belt section (not shown) of conveyor belt 514.Each belt section can have a machine-readable code tied to the orderwhich is within the belt section. The machine-readable code of the beltsection and the related order information could be communicated to theshop floor system 512 from the equipment which assembled the orders. Inany embodiment, preferably the orders are conveyed to the system 500 inthe same sequence that the customized labels for the orders are presenton a reel, and/or preferably the product cartons within an order areconveyed to the system 500 in the same sequence that the labels for theorders are present on the reel. Preferably, the cartons are conveyed tothe label applicator on a one carton-wide conveyor 514 in exactly thesequence of the usable labels on the reel.

[0048] The cartons are conveyed to the label applicator 513. A producthandler e.g. a robotic arm (not shown) may be used to pick product offthe conveyor and place the product into the label applicator 513. Usefullabelling equipment is commercially available. As each product receivesa label it is preferably pushed or placed on a second conveyor 517 whichtransports the products to a final verification, packaging and shippingarea (not shown). The products are preferably maintained in the samesequence, preferably with spaces between individual orders on conveyor517.

[0049] Preferably, the label applicator 513 will only apply a label on acarton after verifying that the proper carton is present by reading theidentification means on the conveyor section (if applicable) via areader (not shown), and/or by reading the identification means on thecarton via a reader (not shown), and/or by reading the labelidentification means via a reader (not shown). The label applicator 513will automatically skip the labels on the reel, which are to bediscarded. (The shop floor control system 512 provides the trackinginformation on the labels as recorded in database 60 to the labelapplicator 513.) The label applicator 513 also preferably comprises aninspection mechanism (not shown) which makes sure each label is in theproper position and without wrinkles prior to allowing a carton to beconveyed to shipping. If the inspection mechanism, such as a visionsystem, or an operator does not pass a labeled product, preferably thecartons which do not pass inspection are discarded and the method willbe repeated from the beginning for those cartons, and the rest of thecartons in a single order will be set aside. If there is an error in theapplicator 513 that requires an operator's attention, the operator mayuse the handheld scanner 519 to communicate to the label control system503 that certain labels should be discarded, which will be noted bydatabase 60 and the shop floor controller 512. This step can be done atany point in the method of printing or otherwise producing the labeledproduct.

[0050] The label applicator 513 preferably continues the verifying,labeling, and inspection steps until all the labels on the reel havebeen put on cartons. When the reel has no more labels to apply, a signalto an operator will indicate that the reel 551 should be changed, andeither the operator can place whichever reel he/she wants onto the labelapplicator 513, or the shop floor controller 512 will communicate to theoperator the next reel 551 to put on the label applicator 513, and theprocess of applying the labels will continue.

[0051] Before and/or after the application of the customized graphics,the packaging may have no human-readable identification of theprescription of the product and may only comprise a machine-readableidentification means which is used to track the product throughmanufacturing and shipping. The customized graphics preferably willidentify who the product is for, and may not indicate any prescriptioninformation. This is particularly beneficial to prevent the product frombeing provided to a person who does not have a proper prescription forthe product.

[0052] While there has been shown and described what are considered tobe preferred embodiments of the invention, it will, of course, beunderstood that various modifications and changes in form or detailcould readily be made without departing from the spirit of theinvention. It is, therefore, intended that the invention be not limitedto the exact form and detail herein shown and described, nor to anythingless than the whole of the invention herein disclosed as hereinafterclaimed.

We claim:
 1. Packaging for housing at least one prescription productcomprising customized graphics on at least some surface area of saidpackaging, said customized graphics being selected by the individualdoctor prescribing said prescription product or the patient to receivesaid prescription product.
 2. The packaging of claim 1 wherein saidcustomized graphics are specified at the time an order for saidprescription product is placed.
 3. The packaging of claim 1 wherein thecustomized graphics identifies the person for whom the prescriptionproduct is for.
 4. The packaging of claim 3 wherein said packaging doesnot identify the prescription.
 5. The packaging of claim 1 wherein thecustomized graphics identifies said doctor prescribing said prescriptionproduct.
 6. The packaging of claim 1 wherein said prescription productis shipped from the manufacturer having said customized graphics on saidpackaging.
 7. The packaging of claim 1 wherein said packaging comprisesprimary packaging and secondary packaging and said customized graphicsare present on at least some surface area of said primary packaging orsaid secondary packaging.
 8. The packaging of claim 7 wherein saidcustomized graphics are present on at least some surface area of saidprimary packaging.
 9. The packaging of claim 1 wherein said prescriptionproduct is a contact lens.
 10. The packaging of claim 9 wherein saidpackaging comprises primary packaging and secondary packaging and saidcustomized graphics are present on at least some surface area of saidprimary packaging.
 11. The packaging of claim 10 wherein said primarypackaging is a blister pack comprising a bowl and lidstock, wherein saidcustomized graphics is present on said lidstock.
 12. The packaging ofclaim 11 wherein said graphics are printed onto said lidstock.
 13. Thepackaging of claim 11 wherein said graphics are printed onto a labelwhich is adhered to said lidstock.
 14. The packaging of claim 9 whereinsaid packaging comprises primary packaging and secondary packaging andsaid customized graphics are present on at least some surface area ofsaid secondary packaging, said secondary packaging being a carton. 15.The packaging of claim 14 wherein said customized graphics are printedonto said carton.
 16. The packaging of claim 14 wherein said graphicsare printed onto a label which is adhered to said carton.
 17. Thepackaging of claim 1 wherein said graphics comprise alphanumericcharacters.
 18. The packaging of claim 1 wherein said graphics comprisepictures.
 19. The method of producing customized packaging which housesat least one prescription product, wherein said packaging is customizedby the individual doctor prescribing and/or said patient receiving saidat least one prescription product comprising the steps of: receiving anorder for at least one prescription product from said doctor or a refillorder from said patient; and printing out customized graphics specifiedby said doctor or said patient for said package for at least oneprescription product.
 20. The method of claim 19 wherein said printingstep entails printing said customized graphics on primary packaging forsaid prescription product.
 21. The method of claim 19 wherein saidprinting step entails printing said customized graphics on secondarypackaging for said prescription product.
 22. The method of claim 19wherein said printing step entails printing said customized graphicsonto a label.
 23. The method of claim 22 further comprising the step ofvarnishing the label.
 24. The method of claim 22 wherein after saidprinting step the method further comprises the step of adhering saidlabel onto said packaging.
 25. The method of claim 19 wherein theprescription product is a contact lens.
 26. The method of claim 22wherein said label has a label identification means.
 27. The method ofclaim 26 wherein said packaging has a product machine readable code, andsaid method further comprises the step of checking said labelidentification means and said product machine readable code before saidadhering step.
 28. The method of claim 27 wherein said method furthercomprises the step of picking said prescription product in customarypackaging from inventory and diverting it to a customized graphicsprinting system prior to said checking step.
 29. The method of claim 19wherein said printing step is performed by a customized graphicsprinting system.
 30. A customized graphics printing system for addingcustomized graphics to packaging for a prescription product comprising:a computer for receiving order information for a prescription productand for the customized graphics to be printed on the packaging for saidprescription product; and a printer for printing out said customizedgraphics for said packaging for said prescription product.
 31. Thesystem of claim 30 further comprising a varnishing application apparatusfor applying varnish to said packaging.
 32. The system of claim 30wherein said customized graphics is printed on a label, and each labelhas a unique identification means.
 33. The system of claim 32 whereineach of said labels is for a particular ordered prescription product,and said system matches up said prescription product with said label.34. The system of claim 30, further comprising a quality check station.35. The system of claim 33, further comprising a label applicator.